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PROTEA P2000 Series Operating Manual

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P2000
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Operating Manual

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  • Page 1 P2000 Analyser Unit Operating Manual...
  • Page 2 Protea Published by Protea. All possible care has been taken in the preparation of this publication, but Protea and its agents and distributors, accept no liability for any inaccuracies that may be found. Protea reserves the right to make changes without notice both to this publication and the products which it describes.

  • Page 3: Table Of Contents

    Contents 1 Introduction About this manual About the P2000 series P2000 - an overview Analyser Identification Further information 2 Installation Introduction Unpacking the system components Pre-installation information Preparing the process gas duct Preparing the Analyser Unit for Wiring Wiring Table...
  • Page 4 Introduction Quality assurance during production Allowed environments Installation additional requirement Maintenance additional requirements Conditions of Safe Use Appendix B – Quality Standard for Instrument Air Supplied to Protea Analysers Introduction Appendix C - In-Situ Heater Introduction In-Situ Heater description Fitting the In-Situ Heater...

  • Page 5: Introduction

    This manual is intended to assist the user in the safe and efficient installation, operation and maintenance of the P2000 series of analyser units. It has been written in accordance with the requirements of British Standard BS4884 Technical manuals Part 1: 1992.

  • Page 6: P2000 - An Overview

    Analyser Unit. A PT100 platinum resistance thermometer is situated in the sample cell. This provides temperature information to the P2000 series, which acts as the basis for the temperature compensation.
  • Page 7 1 Introduction Figure 1-2 P2000 system schematic Control Unit Stack P2000 Optional Outputs 110V / 240V Local PSU 110V / 240V Calibration Gas Issue 1 PROTEA page 7...

  • Page 8: Screen Displays

    Auto-zero NOW Italics Paragraphs in italics usually indicate background information which may be of benefit to the reader. Groups of words in italics are usually cross-referring the reader to a section or sub-section by name. page 8 PROTEA Issue 1...

  • Page 9: Analyser Identification

    This Operating Manual, should give you all the information you require to install, operate and dispose of your P2000 system. If you require any further information regarding the system or its use, you should contact Protea Ltd., or your Protea distributor or agent as shown in the panel below:...
  • Page 10 P2000 Operating Manual Page intentionally left blank page 10 PROTEA Issue 1...

  • Page 11: Installation

    If there is any discrepancy, or any damage is apparent, do not attempt to install the system. Contact Protea, or your Protea distributor or agent. Issue 1 PROTEA...

  • Page 12: Pre-Installation Information

    • Clean and dry instrument air, (Protea Standard ISO 8573-1 1 2 1 see Appendix B) at up to 10 l/min (intermittent) and 6.0 Bar Gauge maximum (nominal inlet pressure 2.5 to 3 Bar Gauge) is available adjacent to where the AU will be fitted •...

  • Page 13: Preparing The Process Gas Duct

    Figure 2-2. This flange may be manufactured from a 3 inch, 150 lb ANSI flange. This item is available from Protea. The mating surface of the process duct flange must be of a quality that will allow a gas- tight joint to be made when a gasket is used between the flange and the Analyser Unit (or In-Situ Heater if fitted).
  • Page 14 Stack Flange – Good Practice M16 Studs Preferred – With the flange wielded directly to the stack, duct or process pipe Stack, duct or process pipe 50mm Acceptable – With an insulated standoff of up to 50mm Insulation Un-acceptable page 14 PROTEA Issue 1...

  • Page 15: Preparing The Analyser Unit For Wiring

    Option 2 ACWn Software with Remote Power Supply Unit (PSU) Analyser (AU) → Power Option 3 Supply Unit (PSU) → Protea Control Unit Analyser (AU) → Power Option 4 Supply Unit (PSU) 1-0093 → Protea ACWn Software Remove Cover to Access...
  • Page 16 4. Repeat this procedure for all cables as indicated in the wiring table relevant to the installation. a. Connecting additional analysers Analyser 1 → Analyser 2 → Analyser 3 → Analyser 4 b. Connecting Auxiliary Inputs → Analyser Connecting In-Situ Heater → Analyser Figure 2-4 page 16 PROTEA Issue 1...

  • Page 17: Wiring Table

    2 Installation Wiring Table Option 1 - Analyser → Protea Control Unit with Remote Power Supply Unit (PSU) Cable Specification Function Analyser Terminal Box Protea Control Unit 2 Twisted pair with O/All screened Znom TB1 – 1B Data Return B...
  • Page 18 P2000 Operating Manual Option 4 Analyser → Power Supply Unit (PSU) → Protea ACWn Software Protea ACWn Cable Specification Power Supply Unit (PSU) Analyser Terminal Function Software (& TC100I) Data Return 2 Twisted pair with TB1 – 1B TB1 – 7B TB1 –...

  • Page 19: Analyser Covers

    2 Installation Analyser Covers Protea analysers are fitted with two basic types of Cooler / Heater however there are the following exceptions: • Analysers supplied with ATEX / IEC Certification • Special Application Heater / Coolers Refer to order specific drawings in these cases.
  • Page 20 The function of Auto Verification Block is described later. Vortex Air Supply Analyser Mounting Flange Auto Verification Unit In-Situ Probe Analyser Junction Box Under Side of Vortex Cooled Electrically Heated P2000 AC/AVU-V-24V Analyser Cover Figure 2-6 page 20 PROTEA Issue 1...
  • Page 21 20ºC. Services required - A supply of high-pressure plant air at 6.8-8 bar (100 -110 psi) and 311 l/min (11scfm). (Protea Standard ISO 8573-1242 see appendix B). As above, a high alarm on the head temperature is required at +55ºC.

  • Page 22: Auto Zero / Verification Units

    Note: The following services are required: ▪ Clean dry instrument air (Protea Standard ISO 8573-1 1 2 1 see Section 7. page 7-2) at pressure of 1 Bar Gauge above the process gas pressure, up to a maximum 6.8 Bar Gauge. The flow-rate available should be between 0.5 l/min (constant) and up to 10 l/min (intermittent during auto-zero/auto-...

  • Page 23: Verifying Correct Zero / Test Gas Flow Rate

    • Analyser Purge The cast aluminium enclosure containing the main optical components is also continuously purged, the flow rate is controlled using a orifice therefore no adjustment required. Issue 1 PROTEA page 23...
  • Page 24 P2000 Operating Manual Page intentionally left blank page 24 PROTEA Issue 1...

  • Page 25: Operation

    3 Operation Introduction The P2000 Analyser Unit must be operated as part of a system incorporating a Protea Control Unit. There are no user accessible controls or indicators on the P2000 as the whole system operates under the control of the Control Unit. Full operating...
  • Page 26 P2000 Operating Manual Page intentionally left blank page 26 PROTEA Issue 1...

  • Page 27: Technical Description

    IR radiation most readily at wavelengths of 4.4 µm and 2.7 µm. Consequently, these two wavelengths are widely used in the detection and concentration measurement of CO Figure 4-1 Typical absorption spectrum for CO Issue 1 PROTEA page 27...
  • Page 28 In practice, however, there are usually several gases. More than one gas may exhibit absorption at a given wavelength. This effect is termed 'cross-sensitivity', and may be compensated for such that accurate concentrations of individual gases may still be displayed. page 28 PROTEA Issue 1...

  • Page 29: Ir Theory Applied To The P2000

    During live operation of the analyser, the system calculates concentration levels from absorbance levels by continual reference to this look-up table. Issue 1 PROTEA page 29...

  • Page 30: Cross-Sensitivity

    NO concentration. Gas filter correlation Gas filter correlation spectroscopy is used in the P2000 series of IR analysers in order to enhance their sensitivity and reduce their cross-sensitivity to interfering components.
  • Page 31 The signal-noise ratio has been raised by the use of gas filter correlation, permitting the measurement of smaller amounts of gas. Protea uses gas filter correlation in combination with software, which enables complete correction to cross-sensitivity to be achieved, even eliminating the small cross-sensitivities that remain after gas filter correlation cells are used.
  • Page 32 P2000 Operating Manual Figure 4-3 IR absorption spectrum of HCl gas page 32 PROTEA Issue 1...
  • Page 33 4 Technical Description Figure 4-4 Detector responses with HCl sealed cell Issue 1 PROTEA page 33...

  • Page 34: Analyser Unit

    The lens is normally made of calcium fluoride. For measurement of longer wavelengths, a zinc selenide lens is used. Lens materials are selected for their good IR transmission characteristics and their inert nature. page 34 PROTEA Issue 1...
  • Page 35 Outer GRP Cover housing the Auto Verification Unit and Fan or Vortex IP65, NEMA 4X Inner: Aluminium alloy casting with high protection finish, sealed to IP65, NEMA 4X. Operating environment Operating temperature range: -10°C to +55°C. Issue 1 PROTEA page 35...

  • Page 36: Integral Auto Verification Unit

    Auto-zero cycle. The frequency and duration of the flush times in the Auto-zero routine can be altered as described in the Operation section of the ACU Operating Manual. page 36 PROTEA Issue 1...
  • Page 37 Needle valve (Mounted in the manifold)  Void purge Restrictor  Optical purge restrictor Services required: Clean, dry instrument air (Protea Standard 8573-1 1 2 1 see Section 7. page 9) at a maximum of 10 barG Issue 1 PROTEA page 37...
  • Page 38 P2000 Operating Manual Page intentionally left blank page 38 PROTEA Issue 1...

  • Page 39: Maintenance

    It is strongly recommended that if a P2000 system is purchased, a service contract is taken out. This will cover regular cleaning, calibration and routine preventative maintenance. A service contract will assure priority response to emergency call-outs. Please contact Protea or Protea distributors for further information about service contracts. Caution...

  • Page 40: Annual Schedule

     Pt100 platinum resistance thermometer resistance check. The resistance should be 100 + (38/100) x temperature. If the results of any of the above checks cause you any concern, contact Protea, or your Protea Distributer or agent, immediately. Cleaning Please do not attempt to clean any of the optical surfaces within the instrument.

  • Page 41: Field Calibration Check

    1/8 BSP taper male fitting (Pipe thread EN 10226 R1/8); scaled 1 barG FSD  if water concentration is to be checked: Protea Field Calibrator Void pressure Test You will require: A pressure gauge (0 – 3barg) connected to a 150mm length of 6mm flexible pipe.

  • Page 42: Sintered Panel Flow Test

    After allowing enough time for the calibration gas in question to stabilise (around 3 minutes) record the readings. If the displayed concentration reading is within ±2% of actual bottle value no calibration is necessary and the user can go to Step 6. page 42 PROTEA Issue 1...
  • Page 43 To return to the TEST screen simply select the EXIT button shown in figure 3. Figure 4 shows the selection of Hydrogen Chloride from the drop down menu, and a successful calibration. Figure 5-4: Choices in drop down menu Issue 1 PROTEA page 43...
  • Page 44 TEST screens the correct value should be displayed 11) Disconnect the PROTEA Field Calibrator and replace the “Hot Access” blanking plug 12) Using ACU turn on the Auto Zero via the options selection, with ACWn turn on Auto Zero via AutoZero selection (fig.1)

  • Page 45: Fault-Finding

    Figure 5-2 (b) is such that they coincide with the peaks and troughs in the IR signal. If they do not, please contact Protea as your system may need recalibration. DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT ANY ADJUSTMENT OF YOUR AU.

  • Page 46: Repair Policy

    P2000 Operating Manual Repair policy Protea recommends that repairs to the P2000 system are only made by its own trained support staff, or by those of its Protea Distributers world-wide. If you have the necessary technical qualifications, training and experience you may wish to make straightforward repairs in-house.

  • Page 47: Spares List

    If you wish to order a spare part, please contact Protea, or your Protea Distributer or agent. If you require a spare part that is not listed here, please contact Protea, or your Protea Distributer or agent. When ordering spare parts, please quote both the Part Number and the serial number of the part of your system concerned - AU, Control Unit, or ISH.
  • Page 48 5. Locate the Integral IR source by reference to Fig 5-3. 6. Unplug the two-pin (Berg-type) pcb connector on the end of the cable from PL1 on the optical head pcb. Figure 5-4 shows the position of PL1. page 48 PROTEA Issue 1...
  • Page 49 11. Replace the AU inner cover and tighten the eight fixing screws. 12. Replace the AU outer cover. Note: Select manual air purge. When readings have stabilised de-select manual air purge, the perform Auto zero now. Issue 1 PROTEA page 49...

  • Page 50: Changing The Filter Wheel Motor

    15 Connect the motor cable to the connector noted in step 8 above, observing the correct orientation. 16 Restore mains power to the Local PSU. 17 Replace the AU cover and tighten the eight fixing screws. 18 Replace the AU outer cover lid. page 50 PROTEA Issue 1...

  • Page 51: Disposal Instructions

    If you are ever in any doubt about how to dispose of the P2000, you may return it to Protea in the United Kingdom, carriage-paid. Protea will dispose of the system for you. There will be no charge for this service, but neither will you receive any payment or allowance for any components or materials recovered.
  • Page 52 PROCAL 2000 Operating Manual Page intentionally left blank. page 52 PROTEA Issue 1...

  • Page 53: Order-Specific Information

    Introduction This section contains summary installation diagrams and information specific to the P2000 series system with which you have been supplied. The following standard drawings of the version current at date of publication are included as a guide only. Title Installation overview –...
  • Page 54 P2000 Operating Manual Page intentionally left blank page 54 PROTEA Issue 1...

  • Page 55: Appendix A - The P2000 With Atex/Iecex Approvals

    Quality assurance during production To comply with the requirements of the approval, several steps have to occur during production under the terms of the licence M1655 held by Protea. The materials used in safety critical parts are supplied with Certificates of Conformity Certain mechanical parts are inspected to drawing to ensure that critical dimensions are correct and records are kept.

  • Page 56: Allowed Environments

    • The P2000 when fitted with the P2000 ATEX/IEC Cooler Option (Vortex Cover 1-2485) has a Protea Declaration of Conformity to a surface temperature classification of T4, which indicates a maximum surface temperature of 135ºC, and is certified for the ambient temperature range –...

  • Page 57: Installation Additional Requirement

    Laws and regulations about flammable atmospheres that apply to the customer should be observed in addition to these ATEX requirements. The main lens is potted and can only be replaced by Protea. Do not attempt to disturb or maintain. To avoid a possible electrostatic charge, only clean with a damp cloth.

  • Page 58: Conditions Of Safe Use

    4) No unauthorised modifications shall be carried out on any part of the enclosure or to the cabling there to. The main bonded lens can only be repaired by Protea and must not be replaced or repaired by the user.

  • Page 59: Appendix B - Quality Standard For Instrument Air Supplied To Protea Analysers

    Appendix B – Quality Standard for Instrument Air Supplied to Protea Analysers Introduction It is essential that the air used for optical purge, void purge and auto zero is of the required standard. This section describes the quality of air supplied. If in doubt it essential that the Quality of Air is tested to confirm that it meets the required standard as stated below.
  • Page 60 P2000 Operating Manual Quality Standard for Instrument Air Supplied to Protea Analysers The quality of instrument air should meet the Class 1 standard given in ISO 8573-1 The Protea standard is ISO 8573-1 1 3 1 A is the figure for Solid Particulates (A=1) Defined as: - The Maximum number of particulates per m allowed whose size is between 0.1µm...

  • Page 61: Appendix C - In-Situ Heater

    DO NOT CONNECT ANY MAINS CABLE (LINE CORD) TO THE ELECTRICAL SUPPLY UNTIL ALL CONNECTIONS WITHIN THE ISH HAVE BEEN MADE AND THE UNITS ARE SECURELY CLOSED ONCE MORE. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SERIOUS OR FATAL INJURY FROM ELECTRIC SHOCK. Issue 1 PROTEA page 61...
  • Page 62 MAINS INSTALLATION HAS AN ISOLATOR FITTED IN THE SUPPLY, AND THIS SHOULD BE PROVIDED BY THE SITE SUPPLY DISTRIBUTION POINT. 1. Determine voltage of supply 110V or 240V (Others consult Protea Ltd or Protea Distributer) 2. Remove and retain the four screws securing the cover of the ISH junction box.
  • Page 63 If the AU is not to be fitted immediately, fit nuts to the four bolts, and finger-tighten to retain the ISH safely. Once the In-Situ Heater has been fitted, you may go on to fit the Analyser Unit. Issue 1 PROTEA page 63...
  • Page 64 Check that all the connections between the AU and the Control Unit are properly made. Confirm that a steady or slowly switching mains voltage appears between the L and N terminals in the ISH mains connection box. page 64 PROTEA Issue 1...

  • Page 65: Appendix D - Protea Analysers For Us Epa Compliance

    Appendix D - Protea analysers for US EPA compliance Introduction To satisfy the environmental regulations in the USA and some other countries, it is necessary to both check and demonstrate that the analyser is within its quoted calibration accuracy. This requires that the Autozero facility should be augmented by an automatic check of the span calibration of the analyser.

  • Page 66: Operation

    A further function is for the remote start of an Autozero cycle, which overrides the internal automatic timer. This facility is activated by shorting 2 inputs on the Analyser Unit with the volt-free contact. page 66 PROTEA Issue 1...
  • Page 67 1 sec UPDATE (CLOSED) (OPEN) the error accordingly Switch off the span gas PROCESS Energised De-enrgised allowing sample gas to 4 mins FLUSH (CLOSED) (CLOSED) re-enter Figure 1: Table showing solenoid states for AUTOZERO/AUTO CAL Issue 1 PROTEA page 67...

  • Page 68: Action On Calibration Error

    If ‘Print this day’ is selected then the report for that day is printed. Similarly, if ‘Print last 7 days’ is selected then the reports for that period are printed. Electrical connections The electrical connections to enable the Calibration Gas controls are detailed on the Installation Drawing page 68 PROTEA Issue 1...

  • Page 69: Appendix E - Hot Access Port

    1/8 BSP taper plug using PTFE tape to seal the thread. Ensure this is tightened to form a gas tight seal. Issue 1 PROTEA page 69...

  • Page 70: Drawings

    P2000 Operating Manual Drawings Figure G1 – Insulation Jacket. page 70 PROTEA Issue 1...
  • Page 71 Appendix E Figure G2 – Reflector Tube Issue 1 PROTEA page 71...
  • Page 72 P2000 Operating Manual Figure G3 – Water Vapour Line Fitting P2000 page 72 PROTEA Issue 1...

  • Page 73: Appendix F - By Pass

    By- Pass Heater set point the scoop is mounted on the upper By-Pass branch and when the stack temperature is lower than the By-Pass temperature the scoop is mounted on the lower branch. Issue 1 PROTEA page 73...

  • Page 74: Fitting The Optional By-Pass

    The By-Pass is mounted on two 4” 150lb flat face ANSI Flanges with (Not normally supplied by Protea Ltd). The flanges are welded to the stack using, it is important the weld is gas tight. Note the correct orientation of the flange is observed.
  • Page 75 The Heater Assembly can then be removed for inspection. • Before reinstalling ensure all particulates have been removed from the Heater Assembly and By-Pass. • It is important that both gasket between the Heater Assembly and AU are replaced during reassembly. Issue 1 PROTEA page 75...

  • Page 76: Connecting The Heater

    Do not attempt to connect any mains cable (line cord) to the Heater if the voltage configuration of the Heater differs from your local electrical supply voltage. Contact Protea, or your Protea-authorised Protea Distributer. Using an incorrect supply voltage will result in the In-Situ Heater failing to function properly.
  • Page 77 MAINS INSTALLATION HAS AN ISOLATOR FITTED IN THE SUPPLY, AND THIS SHOULD BE PROVIDED BY THE SITE SUPPLY DISTRIBUTION POINT. 10. Determine voltage of supply 110V or 240V (Others consult Protea Ltd or Protea Distributer) 11. Remove and retain the four screws securing the cover of the Heater junction box.
  • Page 78 If the sample temperature is higher than the Heater set point it is necessary to reduce the flow through the By-Pass this can be achieved by introducing a Orifice plate in the branch which does not have the scoop attached. page 78 PROTEA Issue 1...

  • Page 79: Appendix G - In-Situ Steam Heater

    Regulation of the ISSH is controlled by a Steam Regulator and steam trap not supplied with the ISSH Typical Steam Pressure required to maintain the Probe at 150°C is 6 barg. Consult the supplier of the steam regulator for detailed advice and recommendations. Issue 1 PROTEA page 79...

  • Page 80: Fitting The In-Situ Steam Heater

    Observe the temperature of the sample (T Sample) on the TEST screen of the Control Unit, adjust the Steam Regulator until T Sample is maintained at the calibration temperature (T Cal), as stated in the analyser dispatch data Analyser Configuration Sheet. page 80 PROTEA Issue 1...
  • Page 81 If the sample temperature shown on the Control Unit TEST screen is consistently below T Cal, then it is likely that the ISSH is not working properly. Take the following actions: Check setting on the Steam Regulator Issue 1 PROTEA page 81...
  • Page 82 P2000 Operating Manual Page intentionally left blank page 82 PROTEA Issue 1...

  • Page 83: Appendix H - Steam Heated By Pass

    Pass by both the action of the scoop and a “Chimney” effect caused by the dissimilar gas temperature in the stack and By-Pass. It is therefore recommended that the scoop is mounted on the lower branch. Issue 1 PROTEA page 83...

  • Page 84: Fitting The Optional Steam Heated By-Pass

    The By-Pass is mounted on two 4” 150lb flat face ANSI Flanges with (Not normally supplied by Protea Ltd). The flanges are wielded to the stack using, it is important the wield is gas tight. Note the correct orientation of the flange is observed.
  • Page 85 It is important the supplied gaskets are used in the installation Part: 4” 150lb Graphite Gasket Secure the By-Pass to the stack mounted flanges using 8 x M16 nuts & washes per flange. Issue 1 PROTEA page 85...
  • Page 86 If the sample temperature is higher than the Heater set point it is necessary to reduce the flow through the By-Pass this can be achieved by introducing a Orifice plate in the branch which does not have the scoop attached. page 86 PROTEA Issue 1...

  • Page 87: Appendix I - Air Preparation Panel

    As stated on page 7-1 instrument supplied to the analyser must conform to the specification as laid in document: Quality Standard for Instrument Air Supplied to Protea Analysers On installations where the quality of instrument air does not meet the required specification it is strongly recommended that the optional Air Preparation Panel is installed.
  • Page 88 Housing Comment Particulate Filter Remove Filter Bowl to access element Remove Lower section of housing to Membrane Dryer access element Active Carbon Filter Remove Filter Bowl to access element page 88 PROTEA Issue 1...

  • Page 89: Appendix J - P2000 With Mcerts Approval

    050060. The full certificate can be viewed at www.mcerts.net (search for a list of approved instruments and under the manufactures name Protea (being re-issued as Parker Protea)). The current list location is at:- http://www.csagroupuk.org/services/mcerts/mcerts- full certificate detailing the product-certification/mcerts-certified-products.pdf. The performance criteria test results, precautions, application, environment and maintenance requirement is also available on request from Parker Protea.

  • Page 90: Quality Assurance During Production

    Sira each year and an MCERTS Design Schedule is re- issued each year to Protea for this Certificate by Sira to show confirmation of authorisation for all changes to design or manufacture. Note this also applies to all changes (up issues) to the Control Unit Control Unit software.

  • Page 91: In-Service History

    In-service history Date Action Signature...

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